Plenty of us have dreamed about dropping a modern engine like a BMW M140i into an old car like a Ford Popular. One builder is actually doing it, and his latest update ends with the moment every project builder waits for.
The builder behind @bradxholmes is fitting a BMW M140i engine into a 1950s Ford Popular. He came up with the idea three months ago. He describes the car as older than mobile phones, the Beatles, and even the requirement for seat belts.
The Goal: A 10-Second BMW M140i Ford Popular
His aim is simple to say and hard to do. He wants the best sleeper he can build, a car that looks harmless but is unexpectedly fast. He has also always wanted a 10-second car.
Before this episode, he had already mounted the engine, built a custom wiring harness and fabricated a new floor, firewall and rear end. This time, he wants to see the rear wheels turn under the engine’s own power.
Starting Over On The Tunnel
First, he primes the bare metal and seals the joints. He tries a thick sealant first and gives up on it. “I actually hate Tiger Seal,” he says, switching to an easier seam sealer.
Then a bigger problem appears. The propshaft tunnel he built earlier is too wide to fit seats on either side. So he cuts the whole thing out and builds a narrower one, using cardboard templates first and then sheet metal.
“There’s no reference photos, no help, or even anyone I can ask to do it for me,” he says of the custom work.
Seats, Wiring And A Failed Bracket
The seats go in on raised steel bases, bolted through reinforcement plates welded to the floor. An MR2 steering column bolts into the mounts he made earlier.
Not everything works the first time. His aluminium bracket for the BMW gear selector keeps blowing through as he welds it. So he rebuilds it in steel, with race-car-style holes that look good and save a little weight. “If I made out it was perfect all the time, I’d be lying,” he admits.
Next, the whole BMW wiring loom goes in. He bolts down the fuse boxes, modules and earth points, and the battery moves to the boot. BMW gauges and a start button get their own small panel, and the electronic throttle pedal gets a custom bracket.
The Last Part That Didn’t Fit
A specialist made the propshaft for him. However, when he offered it up, the joint at the old rear axle was loose enough to see daylight through it. According to the propshaft maker, that part of the axle had worn out, so he fitted a new one.
What This Build Teaches Anyone Planning An Engine Swap
His build log is a useful reality check for anyone dreaming of a modern engine in a classic:
- Plan the interior early. A tunnel built for the engine can leave no room for seats.
- Mock parts up in cardboard before cutting metal.
- Pick materials you can actually weld well.
- Old axles wear out. Check every joint before blaming new parts.
- Expect a lot of small brackets. They take more time than the big jobs.
Where Things Stand
With fuel coming from a bucket, he sits in the car, presses the start button and selects drive. The rear wheels turn. He calls it a massive milestone and says it won’t be long before his BMW M140i Ford Popular is on the road.
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